公开(公告)号：EP0277082A1

公开(公告)日：1988-08-03

申请号：EP88630002.9

申请日：1988-01-06

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： LaRoche, Evans Allen, Jr.

IPC: C04B35/65 ,  C04B35/10

CPC classification number: C04B35/652 ,  B22F3/00

Abstract: A method of producing shaped, self-supporting ceramic bodies includes preparing a mold by applying a gas-permeable, conformable material (20) to a shape-de­fining surface of a shaped parent metal (10). The gas-­permeable material (20), when set or stable, provides a mold with a shaped surface which is defined by, and is therefore substantially congruent to, the shape-defining surface. Upon heating, the parent metal (10) melts and flows from the mold into a receptacle without disturbing the mold. Oxidation reaction product is then grown by oxidation of the molten parent metal with a vapor-phase oxidant to form an oxidation reaction product which grows into the mold cavity and is shaped by it. A ceramic body is recovered from the mold and has substantially the same shape as the pattern section (12,14,18) of the original shaped parent metal (10).

Abstract translation: 一种制造成形的自支撑陶瓷体的方法包括通过将气体可渗透的适形材料（20）施加到成形母体金属（10）的形状限定表面来制备模具。 透气材料（20）当固定或稳定时，为模具提供由形状限定表面限定并因此与形状限定表面基本一致的成形表面。 在加热时，母金属（10）从模具熔化并流入容器而不干扰模具。 然后通过用气相氧化剂氧化熔融母体金属来生长氧化反应产物，以形成生长到模腔中并由其形成的氧化反应产物。 陶瓷体从模具中回收，并且具有与原始形状母体金属（10）的图案部分（12,14,18）基本相同的形状。

公开(公告)号：EP0272997A2

公开(公告)日：1988-06-29

申请号：EP87630262.1

申请日：1987-12-14

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Kennedy, Christopher Robin ,  Newkirk, Marc Stevens

IPC: C04B35/65 ,  C04B35/10

CPC classification number: C04B35/652

Abstract: The present invention provides a method for pro­ducing a self-supporting ceramic composite by the oxida­tion of a parent metal (10) to form a polycrystalline cera­mic material consisting essentially of the oxidation re­action product of the parent metal (10) with an oxidant, including a vapor-phase oxidant, and, optionally, one or more metallic constituents. A permeable filler material, such as a preform (14), with at least one surface bearing a permeble stratum (18), is contacted with a body of molten parent metal (10) heated to a temperature above its melting point but below the melting point of the oxidation reaction product. At least a portion of the oxidation re­action product is maintained in contact with and between the molten metal (10) and oxidant to transport the molten metal through the oxidation reaction product toward the permeable stratum (18) and into contact with the oxidant so that the oxidation reaction product continues to form at the interface between the oxidant and previously formed oxidation reaction product that has infiltrated the filler material. The reaction is continued to infiltrate at least a portion of the stratum (18) with the oxidation reaction product and to produce an intermediate ceramic body having an adjacent ceramic composite overlaid with a ceramic stra­tum. The ceramic stratum is removed from the underlying ceramic composite to produce a self-supporting ceramic com­posite having the surface established by the permeable stratum (18).

Abstract translation: 本发明提供了一种通过母体金属（10）的氧化来生产自支撑陶瓷复合材料的方法，以形成主要由母体金属（10）与氧化剂的氧化反应产物组成的多晶陶瓷材料，氧化剂包括 气相氧化剂和任选的一种或多种金属组分。 具有至少一个带有渗透层（18）的表面的可渗透填充材料（例如预制件（14））与加热到高于其熔点但低于熔化温度的熔融母体金属（10）的主体接触 点的氧化反应产物。 氧化反应产物的至少一部分保持与熔融金属（10）和氧化剂接触并在熔融金属（10）和氧化剂之间输送熔融金属通过氧化反应产物朝向可渗透层（18）并与氧化剂接触，使得 氧化反应产物在氧化剂和预先形成的渗透了填料的氧化反应产物之间的界面处继续形成。 反应继续用氧化反应产物渗透到层（18）的至少一部分，并产生具有覆盖在陶瓷层上的相邻陶瓷复合体的中间陶瓷体。 从下面的陶瓷复合材料中除去陶瓷层，以产生具有由可渗透层（18）建立的表面的自支撑陶瓷复合材料。

公开(公告)号：EP0263051A1

公开(公告)日：1988-04-06

申请号：EP87630161.5

申请日：1987-09-01

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Newkirk, Marc S. ,  Kantner, Robert C. ,  Kennedy, Christopher R.

IPC: C04B35/65

CPC classification number: C04B35/652

Abstract: There is disclosed a method for producing a self-supporting ceramic body by oxidation of a molten precursor metal with a vapor-phase oxidant to form an oxidation reaction product and inducing a molten flux comprising said molten precursor metal through said oxidation reaction product. A second metal is incorporated i said molten flux during the oxidation reaction. The resulting ceramic body includes sufficient second metal such that one or more properties of said ceramic body are at least partially affected by the presence and properties of said second metal.

Abstract translation: 有游离缺失盘的方法用于通过熔融母体金属的氧化生产自支承陶瓷体与气相氧化剂形成的氧化反应产物，以和诱导熔融焊剂通过上述氧化反应产物包含所述的熔融母体金属。 第二金属结合，我说的氧化反应过程中的熔融助熔剂。 所得到的陶瓷体包括足够的第二金属的搜索没有所述陶瓷体的一种或多种性质至少部分地受到存在和所述第二金属的特性。

公开(公告)号：EP0234704A3

公开(公告)日：1988-04-06

申请号：EP87300409

申请日：1987-01-19

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Newkirk, Marc S. ,  Urquhart, Andrew W. ,  Lesher, H. Daniel

IPC: C04B35/65

CPC classification number: C04B35/117 ,  C04B35/652 ,  C04B2235/3217 ,  C04B2235/3418 ,  C04B2235/3826 ,  C04B2235/401 ,  C04B2235/402 ,  C04B2235/428 ,  C04B2235/6028 ,  C04B2235/80 ,  Y10T428/249987

Abstract: A method of producing a self-supporting ceramic composite body having therein at least one cavity which inversely replicates the geometry of a positive mold of parent metal, includes embedding the mold of parent metal within a conformable bed of filler to provide therein a cavity shaped and filled by the mold. The assembly is heated to melt the parent metal mold, e.g., an aluminum parent metal mold, and contacted with an oxidant to oxidize the molten parent metal to form a polycrystalline material which grows through the surroundings of filler, the molten metal being drawn through the growing polycrystalline material to be oxidized at the interface between the oxidant and previously formed oxidation reaction product whereby the cavity formerly filled by the mold of parent metal is eventually evacuated by the metal. There remains behind a cavity whose shape inversely replicates the original shape of the mold. The method provides ceramic composite articles having therein at least one cavity inversely replicating the shape of the mold which supplied the parent metal for oxidation.

公开(公告)号：EP0262075A1

公开(公告)日：1988-03-30

申请号：EP87630176.3

申请日：1987-09-03

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Newkirk, Marc S. ,  Dwivedi, Ratnesh K. ,  Lesher, H. Daniel ,  Kantner, Robert C.

IPC: C04B35/65

CPC classification number: B28B7/344 ,  B28B7/342 ,  C04B35/652

Abstract: A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix embedding a filler (38) includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal with an oxidant and, optionally, one or more metallic constituents, and the filler (38) embedded by the matrix. The method includes heating the parent metal to provide a first source (36) of molten parent metal and a reservoir (34) of molten parent metal and contacting the first source (36) of molten parent metal with a permeable bedding of filler (38). The first source (36) of molten parent metal is reacted with the oxidant to form the oxidation reaction product and is replenished from the reservoir (34) as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired boundary and thereby embed at least a portion of the bedding of filler (38) within the oxidation reaction product to form the ceramic composite structure. The bedding of filler (38) may have any suitable shape, including that of a hollow body, the interior of which is contacted by the first source (36) of molten parent metal to grow the oxidation reaction product through the shaped, hollow body of filler.

Abstract translation: 一种生产自支承陶瓷复合结构，其包括一个陶瓷基体中嵌入填充材料（38）的方法包括氧化母体金属形成多晶材料与氧化剂包括母体金属的氧化反应产物和任选的一种或多种 金属成分，和由基体埋置填料（38）。 该方法包括加热所述母体金属，以提供熔融母金属的第一源（36）和熔融母金属的储存器（34），并与可渗透的填料床上用品接触的熔融母金属的第一源（36）（38） ， 熔融母金属的第一源（36）与氧化剂反应形成氧化反应产物，并从所述储存器（34）补充作为反应持续一段时间，足以使氧化反应产物生长到期望的边界，从而 氧化反应产物内嵌入至少填料（38）的床上用品的一部分，以形成陶瓷复合结构。 填料（38）的床上用品可具有任何合适的形状，包括做了空心体的，所有的内部是通过熔融母金属的第一源（36）通过的成形，中空体中生长的氧化反应产物接触 填料。

公开(公告)号：EP0261070A1

公开(公告)日：1988-03-23

申请号：EP87630196.1

申请日：1987-09-16

Applicant: LANXIDE TECHNOLOGY COMPANY, LP. ,  ALCAN INTERNATIONAL LIMITED

Inventor： Park, Eugene Sangmoo ,  Poste, Steven Douglas

IPC: C04B38/00 ,  C04B35/65

CPC classification number: C04B35/652 ,  C04B38/0025 ,  C04B35/00 ,  C04B38/0058

Abstract: Ceramic foams in which the open cells (3) are connected by a three dimensional, substantially continuous ceramic matrix formed of interconnected hollow ligaments (5), are made from an open-cell, reticulated precursor metal, i.e. a metal foam. The precursor metal first is treated so as to allow a support coating to form thereon, and thereafter the coated precursor is heated above the melting point of the metal in the presence of an oxidant to form an oxidation reaction product.

Abstract translation: 通过由互连的中空韧带（5）形成的三维，基本上连续的陶瓷基体连接开孔（3）的陶瓷泡沫体由开孔，网状前体金属即金属泡沫制成。 首先处理前体金属以便在其上形成载体涂层，然后在氧化剂存在下将涂覆前体加热到高于金属的熔点以形成氧化反应产物。

公开(公告)号：EP0261067A2

公开(公告)日：1988-03-23

申请号：EP87630187.0

申请日：1987-09-10

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Newkirk, Marc S.

IPC: C04B41/83

CPC classification number: C04B41/009 ,  C04B35/652 ,  C04B41/48 ,  C04B41/83 ,  Y10T428/12042 ,  Y10T428/12111 ,  Y10T428/12153 ,  Y10T428/12167 ,  Y10T428/249956 ,  Y10T428/249972 ,  C04B41/53 ,  C04B35/00 ,  C04B38/00

Abstract: A method of producing self-supporting ceramic bodies (12) having a polymer component, which includes first providing a self-supporting ceramic body (12) com­prising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal with an oxidant, and (ii) interconnected porosity (13) at least partially accessible from one or more surfaces of said ceramic body. The polymer is disposed or formed within the interconnected porosity (13). The polymer is situa­ted so as to alter, modify or contribute to the proper­ties of the ceramic body (12) originally formed.

Abstract translation: 具有聚合物组分生产自支承陶瓷体的方法（12），其中包括首先提供的自支撑陶瓷体（12），包括：（i）与在氧化剂根据一种熔融母体金属氧化形成多晶氧化反应产物 ，和（ii）互连孔隙（13）至少部分地从所述陶瓷体的一个或多个表面接近。 所述聚合物被布置或互连孔隙（13）内形成。 聚合物位于以改变，修改或有助于陶瓷体（12）最初形成的性质。

公开(公告)号：EP0261066A2

公开(公告)日：1988-03-23

申请号：EP87630186.2

申请日：1987-09-10

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Newkirk, Marc S. ,  White, Danny R. ,  Dwivedi, Ratnesh K.

IPC: C04B35/65

CPC classification number: C04B35/652

Abstract: A method for producing a self-supporting ceramic composite which comprises preparing a polycrystalline material as the oxidation reaction product of a parent metal with a vapor-phase oxidant, comminuting the resulting material to a particulate, forming a permeable mass of said particulate as filler, and infiltrating said particulate with an oxidation reaction product of a parent metal with a vapor-phase oxidant, thereby forming said ceramic composite.

Abstract translation: 一种自支撑陶瓷复合材料的制造方法，其特征在于，制备作为母金属与气相氧化剂的氧化反应产物的多晶材料，将得到的材料粉碎成粒状，形成作为填料的所述粒子的渗透性物质， 并用母体金属的氧化反应产物与气相氧化剂渗透所述颗粒，由此形成所述陶瓷复合材料。

公开(公告)号：EP0261060A2

公开(公告)日：1988-03-23

申请号：EP87630180.5

申请日：1987-09-10

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Aghajanian, Michael K. ,  White, Danny R. ,  Zwicker, Harry R.

IPC: C04B35/65 ,  C04B38/06 ,  B28B1/00 ,  B28B7/34 ,  B28B3/02 ,  C22C29/12

CPC classification number: B28B3/025 ,  B28B1/00 ,  B28B7/342 ,  C04B35/652 ,  C04B38/061 ,  C04B35/00 ,  C04B38/0051 ,  C04B38/007 ,  C04B38/065 ,  C04B38/069 ,  C04B41/5025

Abstract: A method is provided for producing a self-­supporting ceramic body comprising a polycrystalline ma­terial comprised of the oxidation reaction product of a parent metal (10) and having therein one or more channels which inversely replicate the geometry of a configured fugitive metal (6). The method includes providing an assembly of the configured fugitive metal (6) and the parent metal (10), optionally including a bed of per­meable filler (4), and heating the assembly to form a body of molten parent metal. The molten parent metal is oxidized under selected conditions to grow the polycry­stalline material to engulf the configured fugitive me­tal (6) (and to infiltrate the filler (4), if the filler (4) is present) and to cause the fugitive metal (6) to disperse into the engulfing polycrystalline material thereby leaving behind as the one or more channels the space formerly occupied by the configured fugitive me­tal (6). The method provides self-supporting ceramic bodies having therein one or more channels inversely replicating the shape of the configured fugitive metal (6).

Abstract translation: 提供了一种用于生产自支撑陶瓷体的方法，其包括由母体金属（10）的氧化反应产物组成的多晶材料，并且在其中具有一个或多个通道，其反复地构成配置的短暂金属（6）的几何形状。 该方法包括提供配置的短暂金属（6）和母体金属（10）的组件，任选地包括可渗透填料床（4），并加热组件以形成熔融母体金属体。 熔化的母体金属在选择的条件下被氧化以生长多晶材料以吞没配置的短效金属（6）（并且如果存在填料（4））并渗透填料（4），并导致短暂的金属（6 ）分散到吞没的多晶材料中，从而留下作为一个或多个通道的空间，该空间原先由配置的短暂金属（6）占据。 该方法提供了在其中具有一个或多个通道的自支撑陶瓷体，其相反地复制了配置的短暂金属（6）的形状。

公开(公告)号：EP0245192A3

公开(公告)日：1988-03-16

申请号：EP87630075

申请日：1987-04-30

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： Newkirk, Marc S. ,  Zwicker, Shirley L.

IPC: C04B35/65 ,  C04B35/71 ,  C04B35/80

CPC classification number: C04B35/652 ,  B29K2303/06 ,  B29L2031/7096 ,  C04B35/71 ,  C04B35/80

Abstract: A method of producing self-supporting ceramic composite bodies of desired shaped by infiltrating a permeable preform with polycrystalline matrix material consisting essentially of an oxidation reaction product obtained by oxidation of a parent metal precursor, such as aluminum, and optionally containing therein metallic constituents. The composite body is formed by contacting a zone of a permeable preform, having at least one defined surface boundary spaced from said contacting zone, with a body of molten metal which is reacted with a suitable vapor-phase oxidant to form an oxidation reaction product. Within a certain temperature region, and optionally with one or more dopants in or on the parent metal or said permeable preform, molten parent metal migrates through previously formed oxidation reaction product into contact with the oxidant, causing the oxidation reaction product to grow into the preform toward said defined surface boundary so as to infiltrate the preform up to said defined surface boundary, and provide the composite structure of desired geometry.